Stalk roll

ABSTRACT

In one embodiment of a stalk roll to be mounted upon a stalk roll drive shaft of a corn harvesting header, the stalk roll comprises a cylindrical shell, at least four flutes affixed to and extending radially from said cylindrical shell, wherein the flutes are arranged in a first group and a second group, wherein the first group and the second group contain an equal number of said flutes, and wherein a peripheral distance between the first group and the second group is greater than a peripheral distance between the flutes within either the first group or the second group.

CROSS REFERENCE TO RELATED APPLICATIONS

This non-provisional patent application claimed priority from and is acontinuation of U.S. patent application Ser. No. 12/985,150 filed onJan. 5, 2011 now U.S. Pat. No. 8,220,237, which application claimedpriority from and was a continuation of U.S. patent application Ser. No.11/823,062 filed on Jun. 26, 2007 now U.S. Pat. No. 7,886,510, whichpatent application claimed priority from and was a continuation-in-partof U.S. patent application Ser. No. 10/623,322 filed on Jul. 19, 2003now abandoned, which application claimed priority from and was acontinuation-in-part of U.S. patent application Ser. No. 10/376,657filed on Feb. 28, 2003 now U.S. Pat. No. 7,373,767, which applicationclaimed benefit of priority under 35 U.S.C. §119(e) of provisional U.S.Pat. App. No. 60/364,813 filed on Mar. 15, 2002. The precedingprovisional and non-provisional patent applications are incorporated byreference herein in their entireties.

FIELD OF THE INVENTION

The apparatus described herein is generally applicable to the field ofagricultural equipment. The embodiments shown and described herein aremore particularly for improved harvesting of corn plants.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

No federal funds were used to develop or create the disclosed invention.

REFERENCE TO SEQUENCE LISTING, A TABLE, OR A COMPUTER PROGRAM LISTINGCOMPACT DISK APPENDIX

Not Applicable

AUTHORIZATION PURSUANT TO 37 C.F.R. §1.171 (d)

A portion of the disclosure of this patent document contains materialwhich is subject to copyright protection. The copyright owner has noobjection to the facsimile reproduction by anyone of the patent documentor the patent disclosure as it appears in the Patent and TrademarkOffice patent file or records, but otherwise reserves all copyrightswhatsoever.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The invention is directed to a stalk roll having a revolving cornstalkengagement gap for a corn header.

2. Description of the Prior Art

In the past thirty years, four external factors have greatly impactedcorn harvesting. First, environmentally friendly residue managementrules mandate that the farmer keep a certain percentage of crop residueon the surface of the land to prevent soil erosion. Second, yields havedoubled through improved genetics, fertilization, populations, and rowspacing. Third, genetics have also improved plant health and stalkvigor. Fourth, harvesting machines are larger with increased horsepower,capacity, ground speed, and the machines utilize corn heads with morerow units.

In combination, these factors require that during separation of a cornplant ear (or “ear”) from a cornstalk (or “stalk”), modern stalk rolls:(1) increase the rate of ear separation; (2) ensure that the corn plantis not severed from its root system; (3) increase the speed at whichcornstalks are ejected from the row unit; (4) retain minimal amounts ofmaterial other than ears (“MOTE”) in the heterogeneous material beingdelivered to the combine for threshing; and, (5) lacerate and/orpenetrate the shell of the stalk to expose the internal portions of thestalk for accelerated decomposition of the stalk.

As shown in FIG. 1, modern corn headers are provided with several rowcrop dividers (snouts) for retrieving, lifting, and directing the rowsof cornstalks toward their respective corn plant engagement chambers.The corn plant engagement chamber is defined herein as the portion ofthe corn head row unit that engages the cornstalk and separates the earfrom the corn plant. FIG. 1A shows the top view of two stalk rolls foundin the prior art. Gathering chains located in the corn plant engagementchamber draw the stalks towards the header. Stalk rolls located beneaththe gathering chains pull the stalks rapidly downward, returning thestalk to the field. These stalk rolls are powered by a gearbox. As thestalk rolls rotate, the flutes on the stalk rolls engage and pull thecornstalks downward. Two stripper plates located above the stalk rolls,with one stripper plate on either side of the corn row, are spaced wideenough to allow the cornstalks and leaves to pass between them butnarrow enough to retain the ears. This causes the ears to be separatedfrom the corn plant as the cornstalk is pulled down through the stripperplates. The stalk rolls continue to rotate and eject the unwantedportions of the corn plant below the corn plant engagement chamber,thereby returning the unwanted portions of the corn plant to the field.

The performance of stalk rolls found in the prior art, as shown in FIGS.3-5, has been found to be less than optimal. Attempts at increasingstalk roll performance and increasing ear separation speed have beenmade by increasing rotational speed of the stalk rolls. This wasunsuccessful because stalk rolls having uniform length flutes rotatingat high speeds simulate a solid rotating cylinder, which restricts entryof the corn plant into the corn plant engagement chamber. The diameterof the simulated rotating cylinder is approximately equal to thedistance from the tip of a first flute on a given stalk roll to the tipof a second flute oriented closest to 180 degrees from the first flute.This rotating cylinder effect prevents individual flutes from engagingthe cornstalk and restricts corn plants from entering the corn plantengagement chamber. Thus, cornstalk engagement is hindered and the cornplant hesitates and does not enter the corn plant engagement chamber.

The prior art has attempted to increase the performance of cutting orchopping stalk rolls by adding more flutes to the stalk rolls. Ineffect, this reduces the performance of the stalk rolls because duringrotation of the stalk rolls, a semi-continuous wall of steel thatrestricts entry of the cornstalk into the corn plant engagement chamber,as noted above. As more flutes are added to the stalk roll, rotation ofthe stalk roll causes the stalk roll to more closely simulate a rotatingcylinder. When viewed along the axis of rotation of the stalk roll (thedirection from which the stalk rolls would approach the cornstalk),adding more flutes restricts the ability of the cornstalks to enter thecorn plant engagement chamber due to interference from the ends of theflutes. The result from higher rotational speeds of the stalk rollsexplained above, or from an increased number of flutes is sometimesreferred to as an eggbeater effect. When the gathering chain paddlepasses above the stripper plates and engages a corn plant that isrestricted from entering the corn plant engagement chamber, it willbreak or sever the cornstalk prior to ear separation. Cornstalkseverance prior to ear separation increases intake of MOTE to thecombine, thereby increasing horsepower and fuel requirements. Thishesitation may also cause ear separation to take place near the openingof the row unit and allow loose ears to tumble to the ground, therebybecoming irretrievable. (See U.S. patent application Ser. No. 10/376,657filed by applicant.)

FIG. 3 shows prior art opposing stalk roll designs utilizing six flutesthat inter-mesh and overlap. When the flutes of this type of stalk rollengage the cornstalk, the flutes alternately apply opposing force. Thisknife edge relationship causes at least two problems. First, the cornplants are violently tossed from side to side causing prematureseparation of loosely attached ears, thereby permitting the ear to fallto the ground and become irretrievable. Second, the cornstalk is cut orsnapped at a node causing long, unwanted portions of the cornstalk andleaves to stay attached to the ear and remain in the row unit. Thiseventually creates a pile of trash or fluff in front of the cross-augerand feeder house and increases the amount of MOTE the combine mustprocess. This problem is compounded as the number of row units per cornhead is increased.

FIG. 4 shows the prior art stalk roll design with intermeshing knifeedges as described in U.S. Pat. No. 5,404,699. As shown, the stalk rollshave six outwardly extending integral flutes. Each flute has a knifeedge that is provided with a leading surface and a trailing surface. Arespective knife edge extends the length of each flute in the directionradially distal from the stalk roll. The leading surface of the knifeedge has a ten degree forward (with respect to the rotation of the stalkroll) slope and the trailing surface has a thirty degree reverse slope(with respect to the rotation of the stalk roll), both of which slopesare defined with respect to a radial plane extending through the vertexof the knife edge and the central longitudinal axis of the stalk roll.Therefore, the leading surface is steeper than the trailing surface ofeach knife edge. The radially extending flutes of the stalk rollslocated in the corn plant engagement chamber are interleaved with oneanother in an intermeshing-type arrangement. The stalk rolls may bemounted in a cantilevered arrangement; or alternatively, in anarrangement employing nose bearings. The stalk roll comprises acylindrical shell formed by two semi-cylindrical pieces that are clampedabout a drive shaft. Bolts extend between the two semi-cylindricalpieces to pull the pieces together, thereby clamping the stalk rolls tothe drive shaft.

This design, upon restricted engagement of the stalk roll with thecornstalk, allows the knife edges to cut stalks before pulling thestalks through the stripper plates to separate the ear from the stalk,effectively leaving the upper portion of the corn plant free to float inthe corn row unit as shown in FIG. 3. This requires the combinethreshing components to process a substantial portion of the stalk;again increasing combine horsepower and fuel requirements.

U.S. Pat. Nos. 4,845,930 and 5,040,361 disclose stalk rolls havinginterleaved canted blades for chopping the cornstalks (not shown). U.S.Pat. No. 4,233,804 discloses a stalk roll having six flutes in whichthree of the flutes are radially aligned with the central longitudinalaxis of the stalk roll (not shown). Other chopping stalk rolls aredisclosed in U.S. Pat. Nos. 3,304,702 and 4,974,402 (not shown).Semi-cylindrical husking rolls have been clamped onto drive shafts bybolts as disclosed in U.S. Pat. Nos. 2,469,687, 2,538,965, and 3,101,720(not shown).

FIG. 5 shows the design disclosed by U.S. Pat. No. 6,216,428, which is astalk roll having bilaterally symmetric flutes with knife edges whichare adjacent and overlap in the shear zone area. This design produces ashearing and cutting of the cornstalk using a scissor configurationproduced by the leading and trailing edges of the opposing knife-edgedflutes. Again, the cornstalks are cut off prior to ear separation. Thisis sometimes referred to as a scissor effect and also results in theneed to process increased amounts of MOTE. As disclosed, the flutes ofthe stalk roll are detachable. The stalk roll of U.S. Pat. No. 6,216,428is designed for use on Case New Holland corn heads that do not requirenose bearings at the entrance (of corn plants) to the stalk rolls tooperate properly and are mounted in a cantilevered arrangement.

Case IH corn heads built prior to development of U.S. Pat. No. 6,216,428used stalk rolls having four knives that are bolted to a solid shaft.Adjacent stalk rolls are registered with one another so that as thestalk rolls are rotated, the knives of the opposing stalk rolls are alsoopposing rather than intermeshing. In an opposing arrangement, theknives come into contact with opposite sides of the cornstalk at thesame general height of the cornstalk, thereby lacerating the cornstalkfor accelerated decomposition. It is important that the blades arecorrectly registered with one another, and that the blades are correctlyspaced from one another. The stalk rolls used on Case IH corn headsrequire nose bearings at the forward end (with respect to the directionof travel of the combine during threshing) of the stalk rolls to operateproperly and may not be mounted in a cantilevered arrangement.

The stated objective of the prior art disclosed in FIGS. 4 and 5 is topromote faster decomposition of the crop residue, increased erosioncontrol, and decreased plugging of tillage tools. However, a finely cutcornstalk that is severed from the ground may actually reduce theerosion protection provided by crop residue because it washes or blowsfrom the field, leaving the soil particles susceptible to erosion due torain or wind. This type of crop residue management system has now beendetermined to be environmentally unfriendly.

SUMMARY OF THE INVENTION

It is an object of the present invention to provide a stalk rollstructure with an improved, unrestricted entry area for the cornstalksinto the corn plant engagement chamber that effectively and efficientlyseparates ears of corn from cornstalks while mutilating the cornstalksduring harvesting to accelerate decomposition.

The stalk rolls of the present invention are to be mounted to and aroundstalk roll drive shafts located on either side of the corn plantengagement chamber (i.e., the portion of the corn head row unit thatengages the cornstalk and separates the ear from the cornstalk). Thestalk roll drive shafts cause the stalk rolls to rotate in oppositedirections to pull the cornstalks downwardly through the stalk rolls sothat the ears of corn are snapped off by the stripper plates locatedabove the stalk rolls. As described in detail below, a cornstalk slotbetween the two opposing stalk rolls is defined, and the orientation andarrangement of the respective flutes on each of two opposing stalk rollscause the cornstalk slot to be void of any flutes (defined as a stalkengagement gap) at least once per revolution of the stalk rolls. Thestalk engagement gap facilitates unrestricted entry of the cornstalkinto the corn plant engagement chamber, decreases the amount of MOTE thecombine processes, and helps to increase decomposition of the cornstalk.

The stalk rolls according to the present invention are fashioned withflutes that may or may not include a knife edge. The flutes may beintegrally formed into the stalk roll or affixed thereto. The flutes ofeach stalk roll are organized in at least two groups, with each grouphaving an equal number of flutes. The circumferential distance betweentwo flutes in a respective group is generally less than thecircumferential distance between any two flutes in adjacent groups.Stalk rolls with flutes arranged according to these specifications areoriented with respect to each other so that at least once during therotation of the stalk rolls, no flutes of any stalk roll restrict theentrance of a corn plant into the corn plant engagement chamber. Becausethe stalk rolls rotate at the same speed, each revolution of the stalkrolls will result in a moment in time in which no flutes of any stalkroll impede the entrance of a corn plant into the corn plant engagementchamber.

The stalk roll may be manufactured as a one-piece stalk roll formed fromductile iron that is engaged with a stalk roll drive shaft. In anotherembodiment of the present invention, the stalk roll may comprise acylindrical shell formed by two semi-cylindrical pieces that are clampedabout a mounting base secured to a drive shaft. In this embodiment,bolts extend between the two semi-cylindrical pieces to pull the piecestogether thereby clamping the stalk rolls to the mounting base which ismounted on the drive shaft. The stalk roll of the present invention maybe manufactured in other ways, as is well known to those skilled in theart; and the flutes may be attached or integrated into the stalk roll orthe cylindrical shell portion thereof in any manner known to thoseskilled in the art.

While the practical advantages and features of the present invention andmethod have been briefly described above, a greater understanding of thenovel and unique features of the invention may be obtained by referringto the drawings and detailed description of the preferred embodimentwhich follow.

DETAILED DESCRIPTION Drawings

FIG. 1 is a top view of a corn head that contains a cross auger, afeeder house, a frame, and multiple row units of the prior art.

FIG. 1A is an exploded top view of a portion of one row unit of FIG. 1of the prior art showing a portion of the corn plant engagement chamber.

FIG. 2 is a cross-sectional view along the plane of A-A of one row unit,the cross auger, the cross auger trough, the feeder house, and thegathering chain from FIG. 1, as disclosed in the prior art.

FIG. 3 is a cross-sectional view of a portion of the corn head shown inFIG. 1 along the plane F highlighting the stalk rolls and stripperplates of one row unit of the prior art engaged with and shearing a cornplant.

FIG. 4 is an end view of a pair of cutting type stalk rolls as disclosedin the prior art.

FIG. 5 is an end view of a pair of shearing-type stalk rolls asdisclosed in the prior art.

FIG. 6 is a top view of a pair of opposing stalk rolls that are thesubject of the present application.

FIG. 7 is a perspective view of a pair opposing of stalk rolls that arethe subject of the present application.

FIG. 8 is an exploded view of a pair of stalk rolls that are the subjectof the present application.

FIG. 9A is an end view of an opposing pair of the present art stalkrolls positioned to illustrate a first moment during which the stalkengagement gap is present.

FIG. 9B is an end view of an opposing pair of the present art stalkrolls at a moment in time later than that depicted in FIG. 9A showingthe stalk rolls rotated so that the stalk engagement gap is no longerpresent due to the first opposing flutes positioned in the cornstalkslot.

FIG. 9C provides an end view of an opposing pair of the present artstalk rolls at a moment in time later than that depicted in FIG. 9Bshowing the stalk rolls rotated so that the stalk engagement gap is notpresent due to the second opposing flutes positioned in the cornstalkslot.

FIG. 9D is an end view of an opposing pair of the present art stalkrolls at a moment in time later than that depicted in FIG. 9C showingthe stalk rolls rotated to a position where the stalk engagement gap ispresent for the second time during one revolution of the stalk rolls.

FIG. 9E is an end view of an opposing pair of the present art stalkrolls at a moment in time later than that depicted in FIG. 9D showingthe stalk rolls rotated so that the stalk engagement gap is no longerpresent due to the third opposing flutes positioned in the cornstalkslot.

FIG. 9F is an end view of an opposing pair of the present art stalkrolls at a moment in time later than that depicted in FIG. 9E showingthe stalk rolls rotated so that the stalk engagement gap is not presentdue to the fourth opposing flutes positioned in the cornstalk slot.

FIG. 10 is an end view of another embodiment of an opposing pair of thepresent art stalk rolls having fifth and sixth flutes with a rotationalposition corresponding to the position of the stalk rolls in FIG. 9A.

FIG. 11 is an end view of an opposing pair of the present art stalkrolls illustrating another embodiment having flutes with knife edges.

DETAILED DESCRIPTION - ELEMENT LISTING ELEMENT ELEMENT # Gathering ChainPaddle 1 Gathering Chain 2 Stripper Plate 3 Row Divider 4 Nose Cone 5Transport Vane 6 Cornstalk Slot 7 Cross Auger Trough 8 Cross Auger 9Cross Auger Flighting 10 Feeder House 11 Stalk Roll (Prior Art) 12 CornPlant Ear 13 Outer Shell of Cornstalk 14 First (right) Stalk Roll 15Second (left) Stalk Roll 16 Cylindrical Shell 17 First Flute 18 SecondFlute 19 Third Flute 20 Fourth Flute 21 Knife Edge 22 Leading Surface 23Trailing Surface 24 Stalk Engagement Gap 25 Fifth Flute 26Semi-Cylindrical Shell (Upper) 27 Semi-Cylindrical Shell (Lower) 28Stalk Roll Drive Shaft 29 Annular Ridge 30 Short Bolt Hole 31 Short Bolt32 Sixth Flute 33 Bolt Receiver 34 Intentionally Blank 35 Long Bolts 36Long Bolt Hole 37 Intermediate Drive Shaft 38 Drive Shaft Bolt 39 SmallPin 40 Large Pin 41

DETAILED DESCRIPTION

The general operation of corn heads having stalk rolls mounted thereonof the type illustrated in FIGS. 6-9 is similar to the operation of cornheads using stalk rolls 12 of the prior art (as illustrated in FIGS.1-5). Although the convention for agricultural machine orientation is todefine relative terms (such as “left” and “right”) from the perspectiveof the machine operator, throughout this application the terms “left”and “right” are defined from the perspective of a corn plant. The powersource for this corn head row unit is provided from a stalk roll driveshaft 29 through a gearbox, as described in the prior art and is wellknown to those skilled in the art and not pictured herein. Each cornhead row unit on a corn harvesting header is provided with a first andsecond stalk roll 15, 16 arranged parallel to one another to make anopposing pair. The first and second stalk rolls 15, 16 are provided withnose cones 5 having transport vanes 6. Immediately behind the nose cones5 are cylindrical shells 17 having a first, second, third, and fourthflute 18, 19, 20 and 21, respectively, mounted along the length of thefirst and second stalk rolls 15, 16 (as can easily be seen in FIG. 6).Each flute 18, 19, 20, 21 may further be provided with a knife edge 22,as is shown in detail in the embodiment depicted in FIG. 11. The knifeedges 22 are substantially parallel to the central longitudinal axis ofthe cylindrical shell 17. As shown in the embodiment in FIGS. 6-9, thestalk rolls 15, 16 may be mounted in the cantilevered manner forrotation by their respective stalk roll drive shafts (not shown),thereby eliminating the need for support brackets or bearings.

As with corn harvesting headers employing stalk rolls 12 of the priorart, the stalk rolls 15, 16 of the present invention pull the cornstalkin a downward motion, causing the corn plant ears 13 to contact thestripper plates 3 and separate from the cornstalk. The flutes 18, 19,20, 21 affixed to the stalk rolls 15, 16 may also act to lacerate orcrush the cornstalk, and also facilitate ejection of the cornstalk fromthe corn plant engagement chamber. Gathering chain paddles 1 affixed togathering chains 2 transport the loose corn plant ears 13 to the crossauger trough 8. The cross auger 9 moves the corn plant ears 13 from thecross auger trough 8 to the feeder house 11, which moves the corn plantears 13 into the remainder of the combine for further processing, all ofwhich is well known to those skilled in the art.

In an embodiment not pictured herein, the stalk rolls 15, 16 may bemanufactured as one-piece, formed from ductile iron that is adapted forengagement upon the stalk roll drive shaft 29. In another embodiment,the first and second stalk rolls 15, 16 may be built as two continuous,integral semi-cylindrical shells to be bolted to a stalk roll mountingbase (not shown) into which the stalk roll drive shaft 29 is inserted,as is best illustrated in FIG. 8. The cylindrical shell 17 may becomprised of two semi-cylindrical shell pieces, an uppersemi-cylindrical shell 27 and a lower semi-cylindrical shell 28, thatare bolted to the intermediate drive shaft 38. The long bolt holes 37and long bolts 36 with nuts or other securing means, along with theshort bolt holes 31, short bolts 32, and bolt receivers 34, form a meansfor mounting the cylindrical shell 17 to the intermediate drive shaft38, which is then mounted to the stalk roll drive shaft 29.

FIG. 8 best illustrates the mounting structure for an embodimentemploying semi-cylindrical shells 27, 28. In one embodiment, eachsemi-cylindrical shell 27, 28 is fashioned with two inwardly extendingannular ridges 30 having short bolt holes 31. Short bolts 32 passthrough the short bolt holes 31 and engage bolt receivers 34 located onan intermediate drive shaft 38. Long bolts 36 pass through the long boltholes 37 of two corresponding upper and lower semi-cylindrical shells27, 28, and with a nut or other securing means clamp thesemi-cylindrical shells 27, 28 together around the intermediate driveshaft 38. The intermediate drive shaft 38 is clamped to the stalk rolldrive shaft 29 by drive shaft bolts 39. In addition, a small pin 40 anda large pin 41 prevent relative rotation between the intermediate driveshaft 38 and the stalk roll drive shaft (not shown in FIG. 8).

Each semi-cylindrical shell 27, 28 may be manufactured having at leasttwo integral flutes. In one embodiment, the flutes are then machined todefine the knife edge 22. Each knife edge 22 has a leading surface 23and a trailing surface 24 that form an acute angle between them ofapproximately forty degrees, as shown in the embodiment pictured in FIG.11. The leading surface is a rearward (with respect to the direction ofrotation of one of the stalk rolls 15, 16 of an opposing pair) slopingsurface, sloping approximately ten degrees from the radial plane definedby the central longitudinal axis of the cylindrical shell 17 and thevertex of the knife edge 22. The trailing surface 24 is a forward (withrespect to the direction of rotation of one of the stalk rolls 15, 16 ofan opposing pair) sloping surface, sloping approximately thirty degreesfrom the radial plane defined by the central longitudinal axis of thecylindrical shell 17 and the vertex of the knife edge 22. Other slopesand angles of the leading surface 23 and the trailing surface 24 may beused without departing from the spirit or scope of the presentinvention. As is well known to those skilled in the art, tungstencarbide may be applied to the trailing surfaces 24 to make the knifeedges 22 self-sharpening. Although not shown, the layer of tungstencarbide is generally between three and twenty thousandths of an inchthick and is induction hardened. As illustrated in FIGS. 6-9, the flutes18, 19, 20, 21 of the opposing first and second stalk rolls 15, 16 areoffset to one another but not interleaved. As those of ordinary skill inthe art will appreciate, the stalk roll design disclosed herein may alsobe implemented with a rounded flute edge or edge that does not haveknife-like characteristics even though these embodiments are notpictured herein. Accordingly, the scope of the present invention is notlimited by type of edge fashioned on the flute or the specificcross-sectional shape of the flute.

The present art alleviates the impediment to flow of cornstalks into thecorn plant engagement chamber (which impediment is a result of theegg-beater effect, as described above) by creating at least one stalkengagement gap 25 in the cornstalk slot 7 per revolution of the stalkroll 15, 16, which is explained in detail below. When the stalkengagement gap 25 is present, corn plant entry into the corn plantengagement chamber is not restricted.

As may be seen in FIGS. 9A-9F, the width of the cornstalk slot 7 isdefined as the distance between the inner periphery of the cylindricalshells 17 of the opposing stalk rolls 15, 16, which width is denoted “W”in FIGS. 9A-10. The height of the cornstalk slot 7 is essentiallyinfinite, though in practicality the ground surface provides a lowerlimit for the cornstalk slot 7. The stalk engagement gap 25, as shown inFIGS. 9A, 9D, and 10, is then defined as the moment(s) during revolutionof the first and second stalk rolls 15, 16 in which none of the flutes18, 19, 20, 21 of the first or second stalk roll 15, 16 are positionedwithin the cornstalk slot 7. FIGS. 9B, 9C, 9E, and 9F illustrate thecornstalk slot 7 after the stalk engagement gap 25 is closed.

FIGS. 9A-9F provide six views of the cornstalk slot 7 at six differentmoments during one revolution of the stalk rolls 15, 16, with thedirection of rotation of the stalk rolls 15, 16 indicated by therespective arrows. As will be explained in detail below, the embodimentshown in FIGS. 9A-9F is configured so that the stalk engagement gap 25is present at two different moments in time during one revolution of thestalk rolls 15, 16; and as will be apparent to those skilled in the art,this is but one of many embodiments the present invention may take.Throughout one revolution of the stalk rolls 15, 16, at any point intime, the flutes 18, 19, 20, 21 may be engaged in five different modesof action upon a cornstalk at any point along the axial length of theflute 18, 19, 20, 21 (depending on the location and orientation of theflutes 18, 19, 20, 21 and the particular embodiment). The five modes ofaction upon the cornstalk are: (1) unrestricted entry of the cornstalkinto the corn plant engagement chamber (which occurs at the moment intime shown in FIGS. 9A and 9D, although restricted entry may occur atother moments in time); (2) flute 18, 19, 20, 21 or knife engagementwith the cornstalk (which may occur at moments in time shown in FIGS.9B, 9C, 9E, and 9F, but may also occur at other moments in time); (3)lacerating and crushing of the cornstalk by the flutes 18, 19, 20, 21 orknives (which may occur at the moments in time shown in FIGS. 9B, 9C,9E, and 9F, but may also occur at other moments in time); (4) earseparation and cornstalk ejection (which may occur at moments in timeshown in FIGS. 9B, 9C, 9E, and 9F, but may also occur at other momentsin time); (5) cornstalk release by the stalk rolls 15, 16 for lateraltravel of the cornstalk (which most often occurs at moments in timeshown in FIGS. 9A and 9D, but may also occur at other moments in time).

FIG. 9A shows the stalk engagement gap 25, and illustrates that when thestalk engagement gap 25 appears, no flutes 18, 19, 20, 21 are located inthe cornstalk slot 7. When the stalk rolls 15, 16 are in this position acornstalk (not shown) may freely enter the cornstalk slot 7 and the cornplant engagement chamber with no restriction. The engagement gap alsoallows cornstalks already positioned between the stalk rolls 15, 16 totravel in a lateral direction to compensate for the forward motion ofthe harvesting machine to which the corn head is attached.

FIG. 9B shows the cornstalk slot 7 at a later moment in time after thestalk rolls 15, 16 have rotated from their positions shown in FIG. 9A.FIG. 9B shows that at this point, the first flute 18 of each stalk roll15, 16 has moved into the cornstalk slot 7 so that there is noengagement gap 25, and the first flutes 18 of the respective stalk rolls15, 16 now engage any cornstalk between the stalk rolls 15, 16. Thisengagement may serve to lacerate or crush the cornstalk, or to pull thecornstalk downward through the corn plant engagement chamber andsubsequently eject the cornstalk depending on the specific embodiment.

FIG. 9C shows the cornstalk slot 7 at still a later moment in timewherein the second flute 19 of each stalk roll 15, 16 has moved into thecornstalk slot 7 so that there is still no engagement gap 25. The secondflutes 19 of each respective stalk roll 15, 16 now engage any cornstalkbetween the stalk rolls 15, 16. This engagement may serve to lacerate orcrush the cornstalk, or to pull the cornstalk downward through the cornplant engagement chamber and subsequently eject the cornstalk dependingon the specific embodiment.

FIG. 9D provides a snapshot of the cornstalk slot 7 at a moment in timelater than the moment depicted in FIG. 9C, and shows the stalkengagement gap 25 present for the second time during this revolution ofthe stalk rolls 15, 16. The stalk engagement gap is present since noflutes 18, 19, 20, 21 are positioned within the cornstalk slot 7 whenthe stalk rolls 15, 16 are positioned as in FIG. 9D, and a cornstalk(not shown) may again freely enter the cornstalk slot 7 and the cornplant engagement chamber with no restriction. Again, the engagement gapalso allows cornstalks already positioned between the stalk rolls 15, 16to travel in a lateral direction to compensate for the forward motion ofthe harvesting machine to which the corn head is attached.

FIG. 9E shows the cornstalk slot 7 at a later moment in time from themoment shown in FIG. 9D wherein the third flute 20 of each stalk roll15, 16 has moved into the cornstalk slot 7 so that there is no stalkengagement gap 25. At this point, the third flutes 20 of the respectivestalk rolls 15, 16 now engage any cornstalk between the stalk rolls 15,16. As with similar moments in time already explained, this engagementmay serve to lacerate or crush the cornstalk, or to pull the cornstalkdownward through the corn plant engagement chamber and subsequentlyeject the cornstalk depending on the specific embodiment.

FIG. 9F shows the cornstalk slot 7 at still a later moment in timewherein the fourth flute 21 of each stalk roll 15, 16 have moved intothe cornstalk slot 7 so that there is still no stalk engagement gap 25.Here, the fourth flutes 21 of the respective stalk rolls 15, 16 engageany cornstalk between the stalk rolls 15, 16. Again, this engagement mayserve to lacerate or crush the cornstalk, or to pull the cornstalkdownward through the corn plant engagement chamber and subsequentlyeject the cornstalk depending on the specific embodiment. As will beapparent to those skilled in the art, the next snapshot in time of thecornstalk slot 7 according to the pattern indicated by FIGS. 9A-9F willbe identical to FIG. 9A, and would provide the last view of one fullrevolution of the stalk rolls 15, 16.

FIGS. 6-9 illustrate the exemplary embodiment wherein the stalk rolls15, 16 and their respective flutes 18, 19, 20, 21 are configured so thattwo stalk engagement gaps 25 appear per revolution of the stalk rolls15, 16. As those of ordinary skill in the art will appreciate, the stalkrolls 15, 16 and their respective flutes 18, 19, 20, 21 may beconfigured so that nearly any number of stalk engagement gaps 25 appearper revolution of the stalk rolls 15, 16. For example, although notshown in the figures herein, one of ordinary skill in the art couldeasily add a fifth flute to the stalk rolls 15, 16 between the fourthand first flutes 18, 21 on each stalk roll 15, 16; and thereby reducethe number of stalk engagement gaps 25 per revolution of the stalk rolls15, 16 from one to two.

In the exemplary embodiment shown in FIGS. 6-9, two structural featuresare necessary to create two stalk engagement gaps 25 per revolution ofthe stalk rolls 15, 16. First, the flutes 18, 19, 20, 21 of each stalkroll 15, 16 must be positioned around the circumference of the stalkroll 15, 16 in a non-equidistant manner. That is, the circumferentialdistance between the first flute 18 and fourth flute 21 is greater thanthe circumferential distance between the third flute 20 and fourth flute21 on each stalk roll 15, 16. Likewise, the circumferential distancebetween the second flute 19 and third flute 20 is greater than thecircumferential distance between the first flute 18 and second flute 19of each stalk roll 15, 16. Second, the first stalk roll 15 of anopposing pair is positioned on its respective stalk roll drive shaft 29so that it is slightly advanced (with respect to rotational positions ofthe flutes 18, 19, 20, 21) compared to the second stalk roll 16 of thepair. During operation, the stalk rolls 15, 16 operate at the samerotational speed so that the difference in positioning is maintainedthroughout operation. Because the stalk rolls 12 of the prior art andthe flutes thereon are not configured to yield any stalk engagementgaps, they essentially create a wall of rotating steel as previouslydescribed, which restricts the entry of the cornstalk into cornstalkslot 7 and the corn plant engagement chamber.

FIG. 10 provides an end view of another embodiment of the improved talkrolls. In this embodiment, a fifth flute 26 is added between the firstflute 18 and second flute 19 so that the distance between the firstflute 18 and the fifth flute 26 is equal to the distance between thesecond flute 19 and the fifth flute 26. A sixth flute 33 has also beenadded between the third flute 20 and the fourth flute 21 so that thedistance between the third flute 20 and the sixth flute 33 is equal tothe distance between the fourth flute 21 and the sixth flute 33. FIG. 10depicts a moment when the stalk engagement gap 25 is present, therebyallowing cornstalks to enter the corn plant engagement chamber. In thisembodiment, as in the embodiment shown in FIGS. 9A-9F, the stalkengagement gap 25 appears twice per revolution of the stalk rolls 15,16.

In an alternative embodiment not shown herein, additional flutes thathave a smaller axial length as compared to the axial length of flutes18, 19, 20, 21 could be placed between all or some of flutes 18, 19, 20,21. (Alternatively some of the original flutes 18, 19, 20, 21 could befashioned with a smaller axial length than the axial length of adjacentflutes 18, 19, 20, 31.) Here, the additional flutes would not extend theentire distance of the cylindrical shell 17. Instead, the additionalflutes would only extend along the cylindrical shell 17 from a pointproximal to the end of the cylindrical shell 17 closest to the crossauger 9 (which may be the same point from which the flutes 18, 19, 20,21 extend, as shown in FIG. 6) to a point distal from the cross auger 9,but not the entire length of the cylindrical shell 7 up to the interfacebetween the cylindrical shell 17 and the nose cone 5. That is, theadditional flutes would not extend radially from the cylindrical shell17 on a portion of the cylindrical shell 17 that is distal from thecross auger 9 (and also distal the connection between said stalk rolldrive shaft 29 and the corn harvesting header). This embodimentfacilitates stalk rolls 15, 16 that are configured so as to provide astock engagement gap 25 along a predetermined axial portion of the stalkrolls 15, 16 that first engage the cornstalk (i.e., a portion distalfrom the cross auger 9) while still providing more flutes to engage thecornstalk in the corn plant engagement chamber on a portion of the stalkrolls 15, 16 proximal to the corn harvester header (which may assist indecomposition of the cornstalk and harvesting speed).

As is apparent from the embodiment shown in FIG. 10, the specific numberand orientation of flutes 18, 19, 20, 21, 26, 33 employed on a stalkroll 15, 16 may vary. Therefore, the precise number of flutes 18, 19,20, 21, 26, 33 employed in a particular embodiment, or the specificorientation thereof in no way limits the scope of the present invention.As long as the flutes 18, 19, 20, 21, 26, 33 are oriented upon the stalkrolls 15, 16 and the stalk rolls 15, 16 are orientated with respect toeach other such that at least one stalk engagement gap 25 appears duringone revolution of the stalk rolls 15, 16, the specific orientation ornumber of flutes 18, 19, 20, 21, 26, 33 are not limiting to the scope ofthe present invention. Furthermore, what is referred to herein as acylindrical shell 17 of the stalk rolls 15, 16 need not be fashioned asa perfect cylinder; rather, it may be fashioned so that thecross-sectional area changes along the axial length, or be fashionedwith any cross-sectional shape that performs in a relativelysatisfactory manner.

Having described the exemplary embodiment as well as alternativeembodiments, other features of the present invention will undoubtedlyoccur to those versed in the art, as will numerous modifications andalterations in the embodiments of the invention illustrated or disclosedherein, all of which may be achieved without departing from the spiritand scope of the invention.

The invention claimed is:
 1. A method of harvesting corn, said methodcomprising: a. mounting a first stalk roll to a first drive shaft forrotation in a first direction, wherein said first stalk roll includes aplurality of radially extending flutes; b. mounting a second stalk rollto a second drive shaft for rotation in a second direction, wherein saidsecond direction is opposite said first direction, and wherein saidfirst stalk roll includes a plurality of radially extending flutes; c.defining an area between said first and second stalk rolls as acornstalk slot, wherein said cornstalk slot has an infinite height and awidth defined by the distance between two parallel vertical lines,wherein a first vertical line is tangent the outer periphery of saidfirst stalk roll on the surface of said first stalk roll that faces saidsecond stalk roll, wherein a second vertical line is tangent the outerperiphery of said second stalk roll on the surface of said second stalkroll that faces said first stalk roll; d. configuring said plurality offlutes on said first stalk roll and said plurality of flutes on saidsecond stalk roll so that a stalk engagement gap is formed in saidcornstalk slot during rotation of said first and second stalk rolls,wherein said stalk engagement gap is defined as a moment in time duringwhich none of said flutes on said first stalk roll and none of saidflutes on said second stalk roll are positioned within said cornstalkslot; e. positioning at least one stripper plate above said first andsecond stalk rolls; and, f. allowing said first and second stalk rollsto engage a corn stalk so as to pull said corn stalk downward.
 2. Themethod according to claim 1 wherein said configuring step furthercomprises ensuring that said first and second stalk rolls arenon-intermeshing during rotation.
 3. The method according to claim 1wherein said configuring step further comprises ensuring that said firstand second stalk rolls are intermeshing during rotation.
 4. The methodaccording to claim 1 wherein said configuring step further comprisesensuring that said first and second stalk rolls are identical to oneanother.
 5. The method according to claim 4 wherein said flutes on saidfirst and second stalk rolls are further defined as having a knife edgeformed by a leading surface and a trailing surface, wherein each saidtrailing surface extends radially from said stalk roll further than eachsaid leading surface.
 6. The method according to claim 4 wherein saidconfiguring step further comprises ensuring that said first and secondstalk rolls are non-intermeshing during rotation.
 7. The methodaccording to claim 4 wherein said configuring step further comprisesensuring that said first and second stalk rolls are intermeshing duringrotation.
 8. A method of removing a corn plant ear from a corn stalk,said method comprising: a. mounting a first stalk roll to a first driveshaft for rotation in a first direction, wherein said first stalk rollincludes a plurality of radially extending flutes; b. mounting a secondstalk roll to a second drive shaft for rotation in a second direction,wherein said second direction is opposite said first direction, andwherein said first stalk roll includes a plurality of radially extendingflutes; c. defining an area between said first and second stalk rolls asa cornstalk slot, wherein said cornstalk slot has an infinite height anda width defined by the distance between two parallel vertical lines,wherein a first vertical line is tangent the outer periphery of saidfirst stalk roll on the surface of said first stalk roll that faces saidsecond stalk roll, wherein a second vertical line is tangent the outerperiphery of said second stalk roll on the surface of said second stalkroll that faces said first stalk roll, and wherein the length of saidcornstalk slot is less than the length of either said first or saidsecond stalk roll; d. configuring said plurality of flutes on said firststalk roll and said plurality of flutes on said second stalk roll sothat a stalk engagement gap is formed in said cornstalk slot duringrotation of said first and second stalk rolls, wherein said stalkengagement gap is defined as a moment in time during which none of saidflutes on said first stalk roll and none of said flutes on said secondstalk roll are positioned within said cornstalk slot; positioning atleast one stripper plate above said first and second stalk rolls; and,e. allowing said first and second stalk rolls to engage a corn stalk soas to pull said corn stalk downward.